Removal and installation of a manual gearbox [Toyota Carina T170]

The CARINA-II vehicles are equipped with a five-speed gearbox. Depending on the engine installed, gearboxes of different types are installed. The most important difference between the gearboxes is the lubricant, the "S50" type gearbox is filled with fluid used in automatic gearboxes, and other gearboxes are filled with regular gearbox oil. Therefore, you should first make sure which gearbox is installed on the vehicle. The gear ratios of the three engines described in this book, i.e. the 1.6L, 2.0L and diesel engines, are different.

Removal and installation the gearbox

Removal and installation of all types of gearboxes are carried out in the same way.

• Disconnect the ground cable from the battery.
• Open the tap and drain the coolant until the fluid level drops below the upper water hose.
• Remove the air filter together with the air intake hose (injection engine).
• Disconnect the wire from the reverse light switch.
• Disconnect the speedometer shaft. To do this, unscrew the knurled nut.
• Disconnect the gear shift cable as shown in Fig. 169. To do this, remove the spring clip and washer and pull the spring clip out of the mount

• Remove the coolant intake. It is secured with a bolt and nut.
• With the S50 type gearbox installed, pull out the spring clip connecting the clutch cylinder hose and the tube and unscrew the gearbox mount. With the C52 type gearbox installed, you can unscrew the clutch slave cylinder from the gearbox and carefully move it to the side without disconnecting the tube. Thanks to this, it is not necessary to bleed the hydraulic clutch system after installing the gearbox.
• Unscrew the lower beam covers (left and right).
• Remove the front and rear transmission suspensions. If a protective cover is installed, remove it first. Then unscrew the bolts on the sides shown in Figure 170 and remove the suspension.

• Remove the engine mount center beam (Fig. 171). The beam is attached on the outside and in the middle.

• Disconnect the drive shafts from the gearbox as described in Chapter 11.1. The shafts are bolted to the drive flanges of the differential axles, or inserted into the differential gears.
• Disconnect the wires from the starter and remove the starter.
• Disconnect the ground wire.
• On all boxes except S50, unscrew the plate from the rear of the engine.
• Raise the gearbox with a jack (place a wooden spacer between the jack and the box) and remove the left engine mount.
• Remove the bolts connecting the gearbox to the engine, lower the left side of the engine and slowly lower the gearbox on the jack.

The gearbox is installed in the reverse order, taking into account the following points:

• Jack up the gearbox to the engine and engage the splined portion of the crankshaft with the hub of the driven clutch disc. Tighten the 12 mm diameter gearbox-to-engine connection bolts to a torque of 65 Nm, 10 mm diameter on the S50 gearbox to 40 Nm, and all other bolts to a torque of 47 Nm.
• Install the left engine mount. Tighten the bolts to 53 Nm.
• Tighten the starter mounting bolts to 40 Nm.
• If the drive shafts are attached to the gearbox with bolts, tighten the bolts to 37 Nm.
• Install the center engine mount beam with a bolt tightening torque of 40 Nm.
• Install the front and rear engine mounts with a bolt tightening torque of 40 Nm.
• Pour oil into the gearbox. In the S50 gearbox, pour 2.6 liters of liquid; pour 2.6 liters of SAE 75V 90 or 80W-90 oil into the C52 box.